Compressible cord reel

ABSTRACT

A compressible reel that includes two flanges, a flange connector, and two core wraps, where the flange connector and core wraps include scoring such that the compressible reel may be compressed substantially flat.

CLAIM OF PRIORITY

This application claims the benefit of priority of U.S. Provisional Patent Application Ser. No. 61/770,644, filed on Feb. 28, 2013.

FIELD OF THE INVENTION

The present invention relates to cord reels for storing electrical and other cords.

BACKGROUND

Long, bulky electric cords are unwieldy items for storage. They are easily tangled if compressed into a box, but take up too much space if laid out outside of a box to avoid tangling. A common solution to this problem is to wrap the cord around a large reel. These reels are generally made of three pieces of rigid plastic—a cylindrical core and two sides on either side of the core. Although such plastic reels address the problem of electric cord storage, as they are rigid and not compressible, they take up a fairly large volume considering the relatively small amount of material inherent in the product. This means that manufacturers have to ship out large volumes with relatively few products within the volume; sellers have to designate a large amount of space for display and storage of items that are fairly inexpensive; and if the end user owns one or more of the product but is not using it, he or she must also designate a fairly large amount of space for storage without utility. Therefore there is a need for a reel sturdy enough to store long, bulky electric cords when in use, but that is compressible while not in use, such as during shipping or storage without an electric cord.

SUMMARY OF THE INVENTION

The present invention is a compressible reel. In its most basic form, the compressible reel of the present invention includes two flanges, a flange connector, and two core wraps, where the flange connector and core wraps include scoring such that the compressible reel may be compressed substantially flat.

Each component of the reel is made of a material sturdy enough to support the weight of an entire wrapped, bulky electric cord, but malleable enough to be scored for folding. The preferred material is corrugated plastic. Corrugated plastic has a grain, and the grain of the corrugated plastic of each component relative to the others is an important aspect of the reel of the present invention, as discussed below.

The reel of the present invention includes two preferably substantially square, flat flanges. The length of each side of the flanges is preferably approximately 26.1″, although the sides may be longer or shorter than this length, and may not be precisely equal in length. The flanges preferably have rounded corners so as to avoid poking handlers of the reel. When it is said that the reel of the present invention includes two “substantially square” flanges, “substantially square” is referring to the possible derivations away from perfect square shape in that the sides may not be precisely equal in length and the corners may be rounded. “Substantially square” should therefore refer to perfectly square shapes, as well as shapes that may not have precisely equal length sides and/or rounded corners.

Each flange includes two flange core wrap slots. The flange flaps of the core wrap come through the flange core wrap slots, as discussed below. Each flange also includes sealing proximate to the flange core wrap slots so as to seal the flange flaps of the core wrap to the flanges. This sealing is preferably metal bolts or rivets, but may be heat sealing, or any other type of sealing that will permanently affix the side flaps of the core wrap to the flanges, such as sealing by sonic welding. Each flange also includes other sealings that seal the flange to the octagon portions of the flange connector, discussed in more detail below. These sealings are preferably heat sealings, but may be metal bolts or rivets, or any other type of sealing that will permanently affix the octagon portions of the flange connector to the flanges, such as sealing by sonic welding. As mentioned above, the flanges have a grain, and this grain has a flange grain direction. The flanges preferably include a center hole, and at least one additional hole, where the center hole is preferably slightly larger than the at least one additional hole. The center hole and at least one additional hole may be used to hang the reel. The flanges also preferably include finger holes at each corner to aid in carrying the reel.

The reel of the present invention also includes a flange connector. The flange connector is made of material of the same thickness as the flanges. The flange connector is a long piece of material that is wrapped around to connect with itself, and the wrapped flange connector connects the two flanges of the reel. When not wrapped, from one end to another, the flange connector is preferably approximately 45.8050″ long, but may be longer or shorter. When wrapped, the flange connector consists of two regular polygons opposite from one another, with the polygons connected by two bridges opposite from one another. The preferred polygon is an octagon, but could be any polygon, such as one with 4, 5, or 6 sides. The preferred distance between opposite sides of the preferred octagon polygon is 14.4125″, but may be greater or less than this distance. As the flange connector is initially a long piece of material, one of the octagons is split in half. Therefore the flange connector has a first end, which is a side of a first half octagon, a first bridge, an octagon, a second bridge, a second half octagon, and a second end, which is a side of the second half octagon. When wrapped, the first and second ends meet so that the first and second octagon halves form a second full octagon opposite the octagon. Each side of the octagon has a length that is preferably approximately 4.2213,″ but may be longer or shorter. It is understood that the dimensions cited above are exemplary, and that the size of the compressible reel of the present invention, including the sizes of its component parts, may vary substantially.

The octagon and first and second half octagons that form an octagon when put together are connected to the centers of the flanges of the reel. Therefore in embodiments of the reel where the flanges include center and additional holes, the octagons of the flange connector have corresponding holes. The first and second half octagons share a center hole, so that each has a semicircular tab indented from the first and second ends, and when the first and second ends meet, the semicircular tabs of each half octagon form the center hole that aligns with the center hole of a flange of the reel and with the center hole of the octagon. The octagon and first and second octagon halves also include sealings with the flanges. As discussed above, these sealings are preferably heat sealings, but may be any type of sealing commonly used in the art.

The first and second bridges of the flange connector connect the first half octagon and the octagon, and the octagon and the second octagon, respectively. There are four bridge single scorings between the first half octagon and the first bridge, between the first bridge and the octagon, between the octagon and the second bridge, and between the second bridge and the second half octagon. These single scorings are a single line of premade scoring across the flange connector that allow the flange connector to easily bend at these places, but is not such a deep scoring that the flange connector could be folded flat at the single scorings. Each bridge also includes a bridge double scoring parallel to the bridge single scorings along the center of each bridge. This double scoring allows the bridge to be folded essentially flat at the double scoring if some pressure is applied. Each of the bridge single scorings and bridge double scorings run perpendicular to the bridge grain direction. Each bridge also includes a connector core wrap slot along the center of the bridge, perpendicular to the bridge double scoring. The connector tabs of the core wraps are placed through the connector core wrap slots to form the reel, as discussed below.

The reel of the present invention also includes two core wraps. The two core wraps are made of slightly thinner material than the flanges and flange connector. This is so that it may fold more easily. The core wraps wrap around the flange connector between the two flanges to form the reel. The core wraps include flange flaps at the center of their long sides, which are the reel flange edges and are in contact with the flanges of the reel. The flange flaps protrude through the flanges and are affixed to the flanges preferably by rivets or metal bolts, as discussed above with reference to the flanges of the reel. The core wraps include connector tabs at the center of their short sides. The connector tabs tuck into the connector core wrap slots of the bridges of the flange connector. When unwrapped the core wraps are long strips of substantially rectangular material, but for the flange flaps and connector tabs. The unwrapped core wraps are preferably approximately 29.4282″ long at their longest points, from the end of one connector tab to the end of the other, but may be longer or shorter. The core wraps are preferably approximately 11.1790″ at their widest width, from the edge of one flange flap to the edge of the other, but may be longer or shorter.

The core wraps include several scorings. The core wraps include a wrap double scoring along the center of the length of the core wrap parallel to the reel flange edges, and extending through the connector tabs. This wrap double scoring is similar to the bridge double scoring of the flange connector in that it allows the core wrap to fold essentially flat when enough force is applied to the wrap double scoring. The core wrap also includes four wrap single scorings perpendicular to the wrap double scoring. Two of the wrap single scorings are disposed on either side of the flange flaps. The other two wrap single scorings are disposed on either side of the two wrap single scorings disposed on either side of the flange flaps. Each wrap single scoring is a distance away from the next that is equal to the length of one side of the octagon. As discussed above, with the preferred octagon polygon, each side of the octagon, and therefore the distance between the wrap single scorings, is approximately 4.2213″. The core wraps have a grain that has a core wrap grain direction that is parallel to the wrap double scorings and perpendicular to the wrap single scorings.

The reel of the present invention may be shifted between a reel position and a compressed position. In either position, the octagon portions of the flange connector are sealed to the flanges and the flange flaps of the core wrap are disposed through the flange core wrap slots and sealed to the flanges. When the reel is in the reel position, it is ready to receive and store an electric cord or any other type of cord that may be wrapped around and stored on a reel. In this position, the core wrap is wrapped around the space between the flanges and the connector tabs of the core wrap are tucked into the connector core wrap slots. In this position, the bridge grain direction is perpendicular to both the flange grain direction and the core wrap grain direction. This antidirectionality of the bridge grain strengthens the reel at these connections where a great deal of pressure will be exerted during the reel's use.

When the reel is in the compressed position, pressure is exerted on the wrap double scorings and bridge double scorings so that they fold essentially flat. As there are several layers of sturdy material pressed together, the reel is not totally flat in the compressed position, but the distance between the flanges is greatly reduced from the reel position. The ability of the compressible reel of the present invention to be compressed flat is a great improvement over prior art. This ability means that more reels may be shipped per volume from the manufacturer, that less space is used for display and storage by the seller, and that less space is used by the owner who is not using the reel. Although the reel of the present invention is envisioned primarily for use with electric cords, it is understood that the reel may be used in conjunction with a variety of products that may be dispensed by reel.

Therefore it is an aspect of the present invention to provide a sturdy cord reel that may be compressed essentially flat when not in use.

It is a further aspect of the present invention to provide a cord reel made of corrugated plastic and using the grain of the corrugated plastic to strengthen the reel.

These aspects of the present invention are not meant to be exclusive and other features, aspects, and advantages of the present invention will be readily apparent to those of ordinary skill in the art when read in conjunction with the following description, accompanying drawings, and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top down view of a flange of the reel of the present invention.

FIG. 2 is a top down view of an unwrapped flange connector of the reel of the present invention.

FIG. 3 is a top down view of a flat, unwrapped core wrap of the reel of the present invention.

FIG. 4 is a perspective view of the conjunction of the flange connector and core wrap of the reel of the present invention.

FIG. 5 is a perspective view of the reel of the present invention in the reel position.

FIG. 6 is a perspective view of the reel of the present invention in the compressed position.

DETAILED DESCRIPTION

Referring first to FIG. 1, a top down view of flange 12 is shown. Two such flanges 12 are included on either side of reel 10 of the present invention. Flange 12 is approximately square, but with rounded corners. Each side has length f of approximately 26.1″. Flange 12 includes finger holes 24, center hole 20, and additional holes 22. Flange 12 also includes flange core wrap slots 26, through which flange flaps 56 of core wrap 18, as shown in FIG. 3, traverse.

Flange flaps 56 are secured to flange 12 with rivets 27. Flange 12 is secured to flange connector 16, shown in FIG. 2, by heat sealings 28. Flange 12 has flange grain direction 29.

Now referring to FIG. 2, a top down view of flange connector 16 is shown when it is unwrapped and flat. Flange connector 16 includes, from left to right as shown, first end 30, first half octagon 34, first bridge 38, octagon 39, second bridge 40, second half octagon 36, and second end 32. Each bridge 38, 40 includes bridge double scoring 42, bridge single scoring 47 on either side, and connector core wrap slot 44. When reel 10 is in compressed position 72, as shown in FIG. 6, pressure is applied to bridge double scoring 42 so that bridges 38, 40 essentially fold in half along bridge double scoring 42. Connector tabs 48, 50 of core wrap 18, as shown in FIG. 3, are tucked into connector core wrap slots 44. Bridges 38, 40 also have bridge grain direction 46, which is perpendicular to scorings 42, 47. When flange connector 16 is wrapped, first and second ends 30, 32 meet to form a full octagon similar to octagon 39. Each of these octagons includes center hole 20, additional holes 22, and heat sealings 28 that align with these features on flange 12, shown in FIG. 1. Each side of octagon 39 has length b, which is approximately 4.2213″. Distance a between opposite sides of octagon 39 is approximately 14.4125″. Flange connector 16 has total length c, which is approximately 45.8050″.

Now referring to FIG. 3, a top down view of unfolded core wrap 18 is shown. Two such core wraps 18 are included in reel 10. Core wrap 18 is made of a slightly thinner material than flanges 12 and flange connector 16. Core wrap 18 is rectangular but for flange flaps 56, extending from either of the centers of the long sides of the rectangle, and connector tabs 48, 50, extending from either of the centers of the short sides of the rectangle. Flange flaps 56 extend through flange core wrap slots 26 of flanges 12, as shown in FIG. 1. Flange flap double scoring 58 allows flange flap 56 to be easily folded to lie flush with flange 12. This means that in reel position 70, as shown in FIG. 5, flange flap double scoring 58 is folded such that flange flaps 56, secured to flanges 12, are perpendicular to the remainder of core wraps 18. In compressed position 72, as shown in FIG. 6, flange flap double scoring 58 is not folded, so that each side of core wrap 18 may lie flush with flanges 12. Flange flaps 56 are affixed to flanges 12 by rivets 27. Connector tabs 48, 50 are tucked through connector core wrap slots 44 of flange connector 16, as shown in FIG. 2. Wrap finger holes 60 are included to ease the removal of connector tabs 48, 50 from connector core wrap slots 44, when necessary. Core wrap 18 includes wrap double scoring 52 along the center of its length and four wrap single scorings 54 perpendicular to wrap double scoring 52, and spaced b apart down the length of core wrap 18. Distance b of core wrap 18, shown in FIG. 3, is the same as distance b of flange connector 16, shown in FIG. 2. When reel 10 is in compressed position 72, as shown in FIG. 6, pressure is applied to wrap double scoring 52 so that core wrap 18 folds essentially in half along wrap double scoring 52. Core wrap 18 has core wrap grain direction 64. Core wrap 18 has length d, which is approximately 29.4282″, and width e, which is approximately 11.1790″.

Now referring to FIG. 4, a perspective view of connector tabs 48 of two core wraps 18 being inserted into connector core wrap slot 44 of bridge 38 of flange connector 16 is shown. It is understood that although the bridge shown in FIG. 4 is labeled “38,” this designation is arbitrary and the bridge shown may also be bridge 40, as shown in FIG. 2. Bridge double scoring 42 is shown and will fold bridge 38 in half when reel 10 is in compressed position 72, as shown in FIG. 6. Wrap double scoring 52 is also shown. Wrap double scoring 52 will fold core wrap 18 in half when reel 10 is in compressed position 72. This view clearly shows bridge grain direction 46 perpendicular to core wrap grain 64. This antidirectionality strengthens reel 10.

Now referring to FIG. 5, a perspective view of reel 10 of the present invention in reel position 70 is shown. In this position, core wrap 18 is wrapped around bridges 38, 40 of flange connector 16 and connector tabs 48, 50 are tucked into connector core wrap slots 44 of flange connector 16 so that flange connector 16 is no longer visible. Wrap single scorings 54 are bent to form the octagonal shape framed by flange connector 16. Wrap double scoring 52 is visible, but flat so that every side of core wrap 18 is perpendicular to flanges 12 on either side of core wrap 18. Core wrap grain direction 64 and flange grain direction 29 are shown. They will be in different relation to each other depending on which side of core wrap 18 is compared. Reel 10 in reel position 70 is extremely sturdy and can easily store even very heavy and/or bulky electric cords.

Now referring to FIG. 6, a perspective view of reel 10 of the present invention in compressed position 72 is shown. Wrap double scoring 52 is folded. Although not visible in this view, it is understood that bridge double scoring 42 is also similarly folded. If pressure were applied on top of flange 12, reel 10 would lie essentially flat. This makes storage and shipping of reel 10 much more efficient.

Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions would be readily apparent to those of ordinary skill in the art. Therefore, the spirit and scope of the description should not be limited to the description of the preferred versions contained herein. 

We claim:
 1. A compressible reel, comprising: two flat flanges of equal size and shape, each of which comprises two flange core wrap slots; a flange connector comprising: three polygon portions, comprising a first half polygon, a full polygon, and a second half polygon, wherein said first half polygon and said second half polygon combined comprise a same shape and size as said full polygon; first and second bridges disposed between said first half polygon and said full polygon, and said full polygon and said second half polygon, respectively, wherein each of said first and second bridges comprises a bridge double scoring and a connector core wrap slot perpendicular to and bisecting said bridge double scoring; four bridge single scorings disposed between said first half polygon and said first bridge; said first bridge and said full polygon; said full polygon and said second bridge; and said second bridge and said second half polygon, respectively, wherein said double scorings of said first and second bridges are parallel to said single scorings; two core wraps, each of which comprises: two long sides perpendicular to two short sides; two flange flaps disposed at a center of each of said long sides, sized and dimensioned to fit through said two flange core wrap slots of said flanges; two flange flap double scorings between said flange flaps and said long sides; two connector tabs disposed at a center of each of said short sides, sized and dimensioned to fit through said connector core wrap slots of said first and second bridges of said flange connector; a wrap double scoring parallel to and half way between said long sides, and extending through said connector tabs; a plurality of wrap single scorings disposed perpendicular to said wrap double scoring; at least four first sealings that seal said two flange flaps of said two core wraps to said two flanges; and at least three second sealing that seal said three polygon portions of said flange connector to said flanges.
 2. The compressible reel as claimed in claim 1, comprised of corrugated plastic.
 3. The compressible reel as claimed in claim 1, wherein said two flanges are substantially square in shape.
 4. The compressible reel as claimed in claim 3, wherein each side of each of said substantially square flange is between 24 and 28 inches long.
 5. The compressible reel as claimed in claim 1, wherein said at least four first sealings between said flange flaps and said flanges are rivets.
 6. The compressible reel as claimed in claim 1, wherein said at least three second sealings between said polygon portions and said flanges are heat sealings.
 7. The compressible reel as claimed in claim 1, wherein said polygon portions of said flange connector are a first half octagon, a full octagon, and a second half octagon.
 8. The compressible reel as claimed in claim 7, wherein: said plurality of wrap single scorings disposed on each of said core wraps is four wrap single scorings; two of said four wrap single scorings are disposed on either side of said flange flaps; and two of said four wrap single scorings are disposed on either side of said two of said four wrap single scorings that are disposed on either side of said flange flaps.
 9. The compressible reel as claimed in claim 7, wherein: each side of each of said substantially square flange is between 24 and 28 inches long; each side of said full octagon of said polygon portions of said flange connecter comprise a length of between 3.5 and 5 inches; said flange connector comprises a total length of between 42 and 50 inches; a distance between opposite sides of said full octagon is between 12 and 17 inches; a distance between said wrap single scorings of said core wraps is equal to said length of each side of said full octagon; said long sides of said core wraps comprise a length of between 26 and 34 inches; and said short sides of said core wraps comprise a length of between 9 and 13 inches.
 10. The compressible reel as claimed in claim 1, comprised of a material comprising a grain, wherein: said flanges further comprise a flange grain direction; said bridges further comprise a bridge grain direction, wherein said bridge grain direction is perpendicular to said bridge single scorings and said bridge double scorings; and said core wrap further comprises a core wrap grain direction, wherein said core wrap grain direction is parallel to said wrap double scoring and perpendicular to said wrap single scorings.
 11. The compressible reel as claimed in claim 10, wherein said material is corrugated plastic.
 12. The compressible reel as claimed in claim 1, wherein each of said flanges comprise a center hole between said two flange core wrap slots and said polygon portions comprise a center hole that aligns with said center hole in said flanges.
 13. The compressible reel as claimed in claim 1, wherein each of said flanges comprises finger holes.
 14. The compressible reel as claimed in claim 1, wherein each of said flanges comprises additional holes.
 15. The compressible reel as claimed in claim 1, wherein said flanges and said flange connector are made of a material with a same thickness and said core wraps are made of a material with a lesser thickness.
 16. The compressible reel as claimed in claim 1, wherein: said flange flaps of said core wraps are disposed through said flange core wrap slots and sealed to said flanges with said first sealing; said polygon portions of said flange connector are sealed to said flanges with said second sealing; said compressible reel is capable of being disposed in a reel position and a compressed position; said compressible reel is disposed in a reel position when: said connector tabs of said core wraps are tucked into said connector core wrap slots of said flange connector; said wrap double scoring of said core wraps are not folded, such that said core wraps are flat; said bridge double scorings of said bridges are not folded, such that said bridges are flat; and said flange flap double scorings of said core wraps are folded at a right angle such that said flap flanges are perpendicular to said wrap single scorings; and said compressible reel is disposed in a compressed position when: said connector tabs of said core wraps are not tucked into said connector core wrap slots; said wrap double scorings of said core wraps are folded; said bridge double scorings of said bridges of said flange connector are folded; and s aid flange flap double scorings of said core wraps are not folded.
 17. The compressible reel as claimed in claim 16, comprised of a material comprising a grain, wherein: said flanges further comprise a flange grain direction; said bridges further comprise a bridge grain direction, wherein said bridge grain direction is perpendicular to said bridge single scorings and said bridge double scorings; said core wrap further comprises a core wrap grain direction, wherein said core wrap grain direction is parallel to said wrap double scoring and perpendicular to said wrap single scorings; and when said compressible reel is disposed in a reel position, said bridge grain direction is perpendicular to said flange grain direction and said core wrap direction.
 18. A compressible reel capable of being disposed in a reel position and a compressed position, and comprised of corrugated plastic comprising a grain, comprising: two substantially square, flat flanges of equal size and shape, each of which comprises two flange core wrap slots and a flange grain direction; a flange connector comprising: a first half octagon, a full octagon, and a second half octagon, wherein said first half octagon and said second half octagon combined comprise a same shape and size as said full octagon; first and second bridges disposed between said first half octagon and said full octagon, and said full octagon and said second half octagon, respectively, wherein each of said first and second bridges comprises a bridge double scoring and a connector core wrap slot perpendicular to and bisecting said bridge double scoring; four bridge single scorings disposed between said first half octagon and said first bridge; said first bridge and said full octagon; said full octagon and said second bridge; and said second bridge and said second half octagon, respectively, wherein said double scorings of said first and second bridges are parallel to said single scorings; and a bridge grain direction, wherein said bridge grain direction is perpendicular to said bridge single scorings and said bridge double scorings; two core wraps, each of which comprises: two long sides perpendicular to two short sides; two flange flaps disposed at a center of each of said long sides, sized and dimensioned to fit through said two flange core wrap slots of said flanges; two flange flap double scorings between said flange flaps and said long sides; two connector tabs disposed at a center of each of said short sides, sized and dimensioned to fit through said connector core wrap slots of said first and second bridges of said flange connector; a wrap double scoring parallel to and half way between said long sides, and extending through said connector tabs; four wrap single scorings disposed perpendicular to said wrap double scoring, wherein: two of said four wrap single scorings are disposed on either side of said flange flaps; and two of said four wrap single scorings are disposed on either side of said two of said four wrap single scorings that are disposed on either side of said flange flaps; and a core wrap grain direction, wherein said core wrap grain direction is parallel to said wrap double scoring and perpendicular to said wrap single scorings; eight rivets, two of which seals each of said flange flaps of said core wraps, extended through said flange core wrap slots, to said flanges; and eight heat sealings, four of which seal one of said flanges to said full octagon and four of which seal the other of said flanges to said first and second half octagons; wherein each of said flanges comprise a center hole between said two flange core wrap slots and said full octagon and said first and second half octagons combined comprise center holes that align with said center hole in said flanges; wherein said compressible reel is disposed in a reel position when: said connector tabs of said core wraps are tucked into said connector core wrap slots of said flange connector; said wrap double scoring of said core wraps are not folded, such that said core wraps are flat; said bridge double scorings of said bridges are not folded, such that said bridges are flat; said flange flap double scorings of said core wraps are folded at a right angle such that said flap flanges are perpendicular to said wrap single scorings; and said bridge grain direction is perpendicular to said flange grain direction and said core wrap direction; wherein said compressible reel is disposed in a compressed position when: said connector tabs of said core wraps are not tucked into said connector core wrap slots; said wrap double scorings of said core wraps are folded; said bridge double scorings of said bridges of said flange connector are folded; and said flange flap double scorings of said core wraps are not folded.
 19. The compressible reel as claimed in claim 18, wherein: each side of each of said substantially square flange is between 24 and 28 inches long each side of said full octagon of said flange connecter comprises a length of between 3.5 and 5 inches; said flange connector comprises a total length of between 42 and 50 inches; a distance between opposite sides of said full octagon is between 12 and 17 inches; a distance between said wrap single scorings of said core wraps is equal to said length of each side of said full octagon; said long sides of said core wraps comprise a length of between 26 and 34 inches; and said short sides of said core wraps comprise a length of between 9 and 13 inches.
 20. The compressible reel as claimed in claim 18, wherein said corrugated plastic comprising said flanges and said flange connector is thicker than said corrugated plastic comprising said core wraps. 